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BILLET BRAKE LEVER KITS
J056582020-01-14
GENERAL
Kit Numbers
41600079, 41600082, 41600146, 41600208, 41600280, 41600304, 41600305
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
Separate purchase of Wheel Bearing Grease (Part No. 99856-92) is required for proper installation of this kit. See a Harley-Davidson dealer.
Proper installation of this kit also requires installing a brake pedal pad, sold separately. Refer to the appropriate parts catalog for an original equipment (OE) replacement rubber pad. See the P&A retail catalog for a selection of accessory brake pedal pads.
Kits 41600304 and 41600305: Separate purchase of new accessory brake pedal pad is required.
WARNING
Rider and passenger safety depend upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00308b)
Kit Contents
See Figure 1 and Table 1.
REMOVAL
  1. See Figure 1. Remove the cotter pin and washer (A) from the master cylinder clevis pin. Discard the cotter pin.
    2. NOTE
    The clevis pin has a slight interference fit. Use pliers to pull the clevis pin from the pushrod. Do not damage mating parts.
  2. Remove the clevis pin (B) from the brake rod. Save for installation. Thoroughly clean and examine parts for wear. Replace if necessary.
  3. Remove the brake lever mounting nut and flat washer and discard. Remove and discard the outer O-ring.
  4. Remove the brake lever by rotating counterclockwise. Lift the master cylinder clevis if necessary. Pull the lever from the shaft. Remove and discard the inner O-ring (C).
  5. Thoroughly clean the lever mounting shaft of grease and dirt.
INSTALLATION
NOTE
This Billet-Style Brake Lever has self-lubricating bushings. However, on FLHT and FLTR models, apply a thin film of wheel bearing grease (Part No. 99856-92, purchased separately) to the mounting shaft and bushings before installation.
1. See Figure 1. Insert new O-rings (3) on either side of the lever bushings. Install the new billet style brake lever (1) onto the shaft.
2. Align the holes in the lever and brake rod and insert the stock clevis pin (B).
3. Install the small saved flat washer onto the clevis pin. Insert the new cotter pin (2).
4. Install the large flat washer (4) and locknut (5) from the kit. Secure locknut. Tighten.
Torque: 20–27 N·m (15–20 ft-lbs) hex locknut
5. Install the brake pedal pad to the brake lever.
WARNING
Be sure the master cylinder relief port is not plugged. A plugged relief port can cause brake drag or lockup and loss of vehicle control, which could result in death or serious injury. (00317a)
WARNING
Contact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
  • If inhaled: Keep calm, remove to fresh air, seek medical attention.
  • If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
  • If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
  • If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Contact Poison Control. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240e)
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c)
6.
NOTE
A bulge may not be seen on models having remote reservoirs.
Verify proper operation of the master cylinder relief port.
a. Position motorcycle and handlebar so master cylinder is level (on some vehicles handlebar configurations the use of a flat jack may help position the vehicle).
b. Remove the reservoir cover.
c. Slowly actuate the brake lever while watching the surface of the brake fluid. A slight spurt of fluid will break the surface if internal components are working properly.
d. Install the reservoir cover. See the service manual for proper torque specification.
WARNING
Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)
7. Check that the stop light goes on when the brake lever is actuated.
WARNING
After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a)
8. Test ride the motorcycle at low speed.
SERVICE PARTS
Figure 1. Service Parts: Rear Brake Lever (Typical Shown)
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Brake lever assembly
Not Sold Separately
2
Cotter pin
515
3
O-ring (2)
11900021
4
Washer, 7/16 inch
6416
5
Locknut, 7/16 inch
7825
Items mentioned in text, but not included in kit.
A
Washer
B
Clevis pin
C
Inner O-ring